Ablation probe with tissue sensing configuration

ABSTRACT

An ablation probe is provided. The ablation probe includes a housing that is configured to couple to a microwave energy source. A shaft extends distally from the housing and includes a radiating section at a distal end thereof. A sensor assembly is operably disposed on the housing and includes a pair of sensor contacts. One or more sensors are positioned adjacent the radiating section and extend along the shaft. The sensor(s) have a pair of sensor contact pads that are positioned on the shaft for contact with the pair of sensors such that during transmission of microwave from the radiating section into target tissue at least one electrical parameter is induced into the at least one sensor and detected by the pair of sensor contacts.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application of U.S. patentapplication Ser. No. 14/064,472 filed on Oct. 28, 2013, now U.S. Pat.No. 9,901,399, which claims priority to U.S. Provisional ApplicationSer. No. 61/738,021, filed on Dec. 17, 2012, the entire contents of eachof which are incorporated herein by reference.

BACKGROUND Technical Field

The present disclosure relates to an ablation probe. More particularly,the present disclosure relates to an ablation probe with one or moretissue sensing configurations.

Description of Related Art

Utilizing microwave thermal therapy to treat target tissue is known inthe art. Specifically, one or more suitable microwave antennas that arecoupled to an energy source may be positioned adjacent target tissue.Subsequently, electrosurgical energy, e.g., microwave energy, may betransmitted to a radiating section of the microwave antenna and isdirected to target tissue, which, in turn, results in thermalcoagulation. Typically, a surgeon relies on one or more imaging devices,systems and/or techniques to facilitate in the microwave thermaltherapy. For example, such imaging devices, systems and/or techniquesmay be utilized to determine placement of the microwave antenna relativeto target tissue, ablation completion of target tissue and/or ablationzone size of treated target tissue.

While the aforementioned imaging devices, systems and/or techniques maywork well in a number of applications, (e.g., determining, for example,placement of the microwave antenna relative to target tissue) suchimaging devices, systems and/or techniques, typically, do not provideautomatic shut off when the microwave antenna is purposefully and/orinadvertently withdrawn from or not fully inserted into target tissue.In either of the foregoing scenarios, unintentional thermal injury to apatient and/or clinician is possible.

SUMMARY

As can be appreciated, an ablation probe with one or more tissue sensingconfigurations may prove useful in the surgical arena. Specifically, oneor more tissue sensing configurations that are configured to detectablation probe placement within tissue can prove advantageous forincreasing performance and/or patient safety.

Embodiments of the present disclosure are described in detail withreference to the drawing figures wherein like reference numeralsidentify similar or identical elements. As used herein, the term“distal” refers to the portion of a surgical instrument that is beingdescribed which is further from a user, while the term “proximal” refersto the portion of the surgical instrument that is being described whichis closer to a user.

An aspect of the present disclosure provides an ablation probe. Theablation probe includes a housing that is configured to couple to amicrowave energy source. A shaft extends distally from the housing andincludes a radiating section at a distal end thereof. A sensor assemblyis operably disposed within the housing and includes a pair of sensorcontacts. One or more sensors are positioned adjacent the radiatingsection and extend along the shaft. The sensor(s) have a pair of sensorcontact pads that are positioned on the shaft for contact with the pairof sensors. During transmission of microwave energy from the radiatingsection into target tissue one or more electrical parameters are inducedinto the sensor(s) and detected by the pair of sensor contacts. Theelectrical parameter(s) may be impedance and/or capacitance. Theelectrical parameter(s) may be induced via an interrogatory pulsegenerated from a circuit of the microwave energy source.

The sensor(s) and the pair of sensor contact pads may be formed from asilver ink deposition that is provided on an exterior surface of theshaft. The silver ink deposition may be provided on the exterior surfaceof the shaft via pad printing, laser ablation and/or direct write. Thesilver ink deposition may include two or more depositions that arespaced-apart from one another forming two or more conductive traces thatculminate at the sensor contact pads.

Moreover, the sensor assembly may include a sensor housing that isconfigured to support the pair of sensor contacts. The sensor contactsof the pair of sensor contacts may be positioned apart from one anotherwithin the sensor housing to contact the sensor contact pads and mayinclude a proximal end and distal end. The distal ends may be disposedin oblique relation with respect to the proximal ends. Each sensorcontact of the pair of sensor contacts may be resilient and configuredto flex when the shaft is inserted through an aperture in the sensorhousing for coupling to the housing. Each sensor contact of the pair ofsensor contacts may be configured to couple to a corresponding lead thatextends within the housing and couples to the microwave energy sourcefor communication with one or more modules associated therewith. Theproximal ends of the sensors may be configured to couple tocorresponding clocking features that are provided on an end cap and hubthat are positioned within the housing. The clocking features may beconfigured to facilitate aligning and coupling the sensor housing to thehousing of the ablation probe.

The radiating section may be configured to transmit microwave energy ata frequency that ranges from about 2300 MHz to about 2450 MHz. Moreover,a polyester heat shrink wrap may be provided along the shaft and coversthe sensor(s). Additionally, a ceramic trocar tip may be provided atdistal tip of the shaft and may be configured to pierce tissue. Further,in-flow and out-flow tubes may be provided on the housing of theablation probe and configured to cool the radiating section of theshaft.

An aspect of the present disclosure provides a method for manufacturinga microwave ablation probe. A housing configured to couple to amicrowave energy source is formed. A shaft having a radiation sectionand one or more sensors including a pair of sensor contacts is formed. Asensor assembly including a sensor housing that couples to a pair ofsensor contacts is formed. The shaft is coupled to the housing such thateach sensor of the pair of sensors contacts a corresponding one of thesensor contacts such that during transmission of microwave energy fromthe radiating section into target tissue one or more electricalparameters may be induced into the sensor(s) and detected by the pair ofsensor contacts.

The method may include forming the sensor(s) including the pair ofsensor contact pads via a silver ink deposition that is provided on anexterior surface of the shaft. The method may include utilizing aprocess such as, for example, pad printing, laser ablation and directwrite to provide the silver ink deposition on the exterior surface ofthe shaft.

Forming the sensor(s) including the pair of sensor contact pads via asilver ink deposition may include forming two or more depositions thatare spaced-apart from one another forming at least two conductive tracesthat culminate at the sensor contact pads.

The method may include utilizing an overmolding process to couple thesensor housing to the pair of sensor contacts. The method may alsoinclude bending each sensor contact of the pair of sensor contacts suchthat the sensor contacts are angled toward one another and arepositioned apart from one another within the sensor housing to contactthe sensor contact pads.

BRIEF DESCRIPTION OF THE DRAWING

Various embodiments of the present disclosure are described hereinbelowwith references to the drawings, wherein:

FIG. 1 is a right, perspective view of an ablation probe having asensing configuration according to an embodiment of the presentdisclosure;

FIG. 2 is a partial, left side view of the ablation probe depicted inFIG. 1 with a left side portion of a housing being removed to illustratea portion of a sensor assembly according to an embodiment of the presentdisclosure;

FIG. 3 is a left, perspective view illustrating a pair of sensorcontacts of the sensor assembly depicted in FIG. 2;

FIG. 4 is a left, perspective view illustrating the sensor assemblycoupled to an end cap of the ablation probe;

FIG. 5 is a cut-away view taken along line segment 5-5 in FIG. 4 with ashaft of the ablation probe removed;

FIG. 6 is a partial, top elevated view of the ablation probe depicted inFIG. 1 with a top portion of a housing being removed and a top portionof a sensor housing removed to illustrate the sensor contacts in contactwith sensor pads disposed on the shaft of the ablation probe;

FIG. 7A is a side view of the shaft including a sensor configurationaccording to an embodiment of the instant disclosure;

FIG. 7B is an enlarged area of detail depicted in FIG. 7A;

FIG. 8A is a side view of the shaft including a sensor configurationaccording to another embodiment of the instant disclosure;

FIG. 8B is an enlarged area of detail depicted in FIG. 8A;

FIG. 9A is a side view of the shaft including a sensor configurationaccording to yet another embodiment of the instant disclosure;

FIG. 9B is an enlarged area of detail depicted in FIG. 9A;

FIG. 10A is a side view of the shaft including a sensor configurationaccording to still another embodiment of the instant disclosure;

FIG. 10B is an enlarged area of detail depicted in FIG. 10A;

FIG. 11 is a side view of the shaft including a sensor configurationaccording to still yet another embodiment of the instant disclosure;

FIG. 12A is a side view of the shaft including a sensor configurationaccording to still yet another embodiment of the instant disclosure;

FIG. 12B is an enlarged area of detail depicted in FIG. 12A;

FIG. 13A is a side view of the shaft including a sensor configurationaccording to still yet another embodiment of the instant disclosure;

FIG. 13B is an enlarged area of detail depicted in FIG. 13A;

FIG. 14A is a side view of the shaft including a sensor configurationaccording to still yet another embodiment of the instant disclosure;

FIG. 14B is an enlarged area of detail depicted in FIG. 14A;

FIG. 15A is a side view of the shaft including a sensor configurationaccording to still yet another embodiment of the instant disclosure; and

FIG. 15B is an enlarged area of detail depicted in FIG. 15A.

DETAILED DESCRIPTION

Detailed embodiments of the present disclosure are disclosed herein;however, the disclosed embodiments are merely examples of thedisclosure, which may be embodied in various forms. Therefore, specificstructural and functional details disclosed herein are not to beinterpreted as limiting, but merely as a basis for the claims and as arepresentative basis for teaching one skilled in the art to variouslyemploy the present disclosure in virtually any appropriately detailedstructure.

In accordance with the instant disclosure, one or more sensorconfigurations are provided on an ablation probe to detect one or moreproperties that may be associated with target tissue and/or a specificsurgical procedure. Specifically, the sensor configuration(s) providesfeedback to a clinician or directly to a source of electrosurgicalenergy, e.g., a microwave generator, to improve overall performance ofthe ablation device and/or safety to a patient or clinician. To thisend, the sensor configuration(s) includes one or more conductive tracesthat are deposited on an exterior surface of a shaft of the ablationprobe and interrogated at a predetermined frequency to measure one ormore electrical properties, e.g., capacitance and/or impedance, that areinduced in the conductive traces.

Turning now to FIG. 1, an ablation probe 2 including a sensorconfiguration 4 according to an embodiment of the present disclosure isillustrated. In accordance with the instant disclosure, sensorconfiguration 4 may also be utilized to serve as centimeter depthmarkings. Ablation probe 2 is configured to electrosurgically treattissue utilizing electrosurgical energy having a frequency that rangesfrom about 2300 MHz to about 2450 MHz. In embodiments, ablation probe 2may be configured to electrosurgically treat tissue utilizingelectrosurgical energy having a frequency that is less than 2300 MHz(e.g., 915 MHz) and greater than 2450 MHz. It has been shown throughempirical testing that utilizing microwave energy from about 2300 MHz toabout 2450 MHz has clear advantages when compared to more traditionalfrequency platforms, e.g., 915 MHz. Specifically, and in accordance withthe instant disclosure, ablation probe 2 utilizes microwave energy thatis provided by a microwave energy source, e.g., a generator 3 (FIG. 1),and transmitted at a frequency that ranges from about 2300 MHz to about2450 MHz to create ablation zones that have a more sphericalconfiguration for a specified range of activation times when compared toconventional ablation probes. Moreover, this higher frequency rangeallows ablation probe 2 to utilize a radiating section 6 (FIG. 1) thatincludes a length that is relatively short when compared to radiatingsections of conventional ablation probes. As can be appreciated,radiating section 6 provides enhanced focus of the microwave energytransmitted therefrom and into target tissue, which, in turn, allows themicrowave energy to penetrate deeper and faster into target tissue,which, in turn, results in a desired tissue effect with shorteractivation times of radiating section 6.

Continuing with reference to FIG. 1, ablation probe 2 includes a housing8 that is formed from one or more suitable materials, e.g., plastic,metal, metal alloy, ceramic, etc. Housing 8 functions as a handle thatmay be grasped by a user and is configured to house one or morecomponents of ablation probe 2. A proximal end of housing 8 operablycouples to a hub 10 (FIG. 1) that couples a cable 12 to ablation probe 2and one or more leads 14, 16 (FIG. 2) that are disposed within housing8. Proximal end 8 also couples to in-flow and out-flow tubes 18, 20(FIG. 2), respectively, that are coupled to a coolant source 5 (FIG. 1)configured to provide one or more suitable coolants, e.g., saline, to ashaft 22 that serves as a cooling jacket and surrounds radiating section6.

Shaft 22 may be formed from any suitable material, e.g., metal, glassfiber, and extends distally from housing 8. In the illustratedembodiment, shaft 22 is formed from glass fiber Shaft 22 includes adistal end 24 (FIGS. 1 and 7A) that includes a ceramic tip 25 (FIGS. 1and 7A) configured to pierce tissue for positioning radiating section 6adjacent target tissue. Shaft 22 also includes a proximal end 26 thatoperably couples to one or more components disposed within housing 8.Specifically, proximal end 26 includes a pair of indents 28 (FIG. 7A)that are configured to couple to a pair of corresponding detents (notexplicitly shown) that are provided within a hub 30 (FIGS. 2, 4 and 6).

Hub 30 defines in-flow ports 32 and out-flow ports 34 that areconfigured to couple to corresponding in-flow tubes 18 and out-flowtubes 20 (FIG. 2). In-flow and out-flow ports 32, 34, respectively,communicate with one or more lumens (not explicitly shown) that extendthrough housing 8 and into shaft 22 forming a closed-loop path forproviding coolant to radiating section 6. Hub 30 includes one or moreclocking features (not explicitly shown) that align with one or morecorresponding clocking features (not explicitly shown) disposed on anend cap 36 (FIG. 4) that operably couples to a distal end of hub 30. Theclocking features on hub 30 and end cap 36 are configured to providepassage for leads 14, 16 so that leads 14, 16 may be coupled to a pairof sensor contacts 38, 40 (FIGS. 2-4 and 6) of a sensor assembly 42(FIG. 2).

Continuing with reference to FIG. 2, sensor assembly 42 is operablydisposed within housing 8 and includes sensor contacts 38, 40 that areconfigured to contact a corresponding pair of sensor contact pads 44(see FIGS. 6-7A for example) positioned on shaft 22. Specifically,during transmission of microwave energy from radiating section 6 intotarget tissue, one or more electrical parameters, e.g., capacitanceand/or impedance, is induced into one or more conductive traces 46(FIGS. 7A-7B) and detected by sensor contacts 38, 40. Alternatively, aseparate interrogation circuit 7 (FIG. 1) may be configured to apply aseparate voltage to conductive traces 46 and measure current associatedtherewith to determine capacitance and/or impedance. In this embodiment,interrogation circuit 7 may be in communication with one or more modules(not shown) of generator 3 and configured to calculate capacitanceand/or impedance. The interrogation frequency utilized may range fromabout 50 KHz to about 4 MHz.

Referring to FIGS. 3-4, sensor contacts 38, 40 are spaced apart apredetermined distance from one another within a sensor housing 48 thatis configured to support sensor contacts 38, 40 (as best seen in FIG.4). Proximal ends 50, 52 of sensor contacts 38, 40, respectively, areconfigured to couple to corresponding leads 14, 16 that extend withinhousing 8 (FIG. 3). Leads 14, 16 couple to the microwave energy sourceto provide communication between sensor contacts 38, 40 and one or moremodules (not explicitly shown) of the microwave energy source.

In the illustrated embodiment, distal ends 54, 56 are offset fromproximal ends 50, 52 (as best seen in FIG. 3) to facilitate contactbetween sensor contacts 38, 40 and sensor contact pads 44. Specifically,distal ends 54, 56 are disposed in oblique relationship with respect torespective proximal ends 50, 52 and are in substantial horizontalalignment with one another.

Referring to FIG. 5, a predetermined gap is provided between the distalends 54, 56 and may be determined during the manufacture process. Moreparticularly, the distance of the gap between distal ends 54, 56 issmaller than an outside diameter of shaft 22; this will facilitatecontact between distal ends 54, 56 and sensor contact pads 44.Specifically, each of distal ends 54, 56 includes a sensor contactsurface 58, 60 (FIGS. 3 and 5) that is configured slide across acorresponding sensor contact pad 44 when shaft 22 is positioned throughan aperture 62 that provides passage through sensor housing 48 (seeFIGS. 4-5). In embodiments, sensor contact surfaces 58, 60 may be biasedoutwardly from distal ends 54, 56 and movable therein. Specifically, asshaft 22 is positioned within aperture 62 the larger diameter of shaft22 causes sensor contact surfaces 58, 60 to translate into distal ends54, 56. As can be appreciated, this reduces the likelihood of sensorcontact surfaces 58, 60 inadvertently scrapping/or scratching off thesilver ink depositions that form sensor contact pads 44 as shaft 22 isinserted through aperture 62. Additionally, distal ends 54, 56 areflexible and configured to flex when shaft 22 is positioned throughaperture 62. Specifically, notched out portions 64 (one of notchedportions 64 is shown in FIG. 4) are provided on sensor housing 48 andallow distal ends 54, 56 to flex or give as shaft 22 is positionedwithin aperture 62. The flexibility of distal ends 54, 56 may beadjusted or varied during the manufacturing process as needed.

With reference now to FIGS. 7A-7B, an embodiment of sensor configuration4 (sensor 4) is illustrated. In the embodiment illustrated in FIGS.7A-7B, sensor 4 is positioned adjacent radiating section 6 and extends apredetermined length along shaft 22. In accordance with the instantdisclosure, sensor 4 is defined by one or more conductive traces 46 thatare formed from a silver ink deposition provided on the exterior surfaceof shaft 22. A silver ink deposition was utilized because of its abilityto withstand EtO (Ethylene Oxide) sterilization. Other types of inkdepositions including but not limited to gold, copper and nickel mayalso be utilized. One or more methods or processes may be utilized fordepositing the silver ink onto the exterior of surface of shaft 22. Forexample, pad printing, laser ablation and direct write are suitablemethods for depositing the silver ink onto the exterior surface of shaft22.

In the illustrated embodiments, the silver ink deposition is utilized toform two or more conductive traces 47 a, 47 b (FIG. 7B) that are spacedapart a predetermined distance from one another. For example, inembodiments, the distance that conductive traces 47 a, 47 b are spacedapart from one another may range from about 0.010 inches to about 0.080inches. As can be appreciated, the distance that separates conductivetraces 47 a, 47 b may be varied or altered during the silver inkdeposition process. Accordingly, in embodiments, the distance thatseparates conductive traces 47 a, 47 b may be less than 0.050 mm orgreater than 0.080 mm.

Continuing with reference to FIG. 7A each of conductive traces 47 a, 47extends from distal end 24 adjacent radiating section 6 to proximal end26 adjacent detents 28 and culminates at sensor contact pads 44 that arealso formed during the aforementioned silver ink deposition process. Thedistance that separates conductive traces 47 a, 47 and sensor contactpads 44 ranges from about 0.050 inches to about 0.100 inches. As can beappreciated, the distance that separates conductive traces 47 a, 47 band sensor contact pads 44 may be varied or altered during the silverink deposition process. Accordingly, in embodiments, the distance thatseparates conductive traces 47 a, 47 b and sensor contact pads 44 may beless than 0.001 mm or less than 0.300 mm. The important part of thisfeature are to have the contact pads spaced far enough apart to ensureelectrical isolation from one another, but large enough pad area toensure contact with the pogo-pin.

FIGS. 8A-15B illustrate various other configurations of sensor 4. Eachof the configurations of sensor 4 shown in FIGS. 8A-15B may be formedutilizing the aforementioned materials and silver ink depositionprocesses. Sensors 4 illustrated in FIGS. 7A-15B may include anysuitable configuration, such as, for example, two horizontal bars (FIGS.8A-8B), two vertical bars (FIGS. 7A-7B), multi-band horizontal bars(FIGS. 9A-9B), spiral bars (FIGS. 10A-10B), or other suitableconfiguration (see FIGS. 11-15B for example). The specific configurationof sensor 4 utilized with ablation probe 2 will depend on a manufacturespreference, a type of surgical procedure, target tissue (e.g., liver,ling, kidney, etc.), signal to noise ration parameters, etc.

A shrink wrap 66 (shown in phantom in FIG. 7A), e.g., polyester heatshrink wrap, is provided along shaft 22 to encapsulate conductive traces47 a, 47 b and sensor contact pads 44. Shrink wrap 66 is utilized tomaintain the structural integrity of conductive traces 47 a, 47 b and/orsensor contact pads 44. Moreover, shrink wrap 66 is utilized to protecta patient from silver bio-incompatibility. Further, it serves as anonstick coating to prevent ablated tissue from sticking to sensor 4,e.g., conductive traces 47 a, 47 b.

In accordance with the instant disclosure, ablation probe 2 isconfigured to function in two modes of operation. Specifically, in afirst mode of operation, e.g., a standard or manual ablation mode,sensor 4 may be configured to detect when ablation probe 2 or componentassociated therewith, e.g., radiating section 6, has been properlyinserted, e.g., fully positioned, within target tissue and may beconfigured to automatically terminate power to ablation probe 2 ifradiating section 6 is inadvertently or purposefully removed from targettissue. In this particular mode of operation, a clinician may positionradiating section 6 of ablation probe 2 within target tissue. One ormore modules associated with generator 3 may be coupled to conductivetraces 47 a, 47 b and configured to send an interrogatory pulse theretoto determine if radiating section 6 has been properly inserted intotarget tissue, e.g., liver tissue. If the module(s) detects apredetermined capacitance and/or impedance induced within conductivetraces 47 a, 47 b, a clinician may initiate the transmission ofmicrowave energy to radiating section 6. It has been shown throughempirical testing that suitable interrogation frequencies forcapacitance may range from about 200 KHz to about 600 KHz. Moreover, ithas been shown through empirical testing that suitable interrogationfrequencies for impedance may range from about 40 KHz to about 600 KHz.In manual mode of operation, generator 3 automatically shuts off ifradiating section 6 is inadvertently or purposefully removed from targettissue during transmission of microwave energy therefrom.

Moreover, in a second mode of operation, e.g., a resection mode, thegenerator may be configured to automatically initiate and terminatepower to ablation probe 2 based on proper insertion of ablation probe 2.In this particular mode of operation, a clinician may position radiating6 of section ablation probe 2 within target tissue. One or more modulesassociated with generator 3 may be coupled to conductive traces 47 a, 47b and configured to send an interrogatory pulse thereto to determine ifradiating section 6 has been properly inserted into target tissue, e.g.,liver tissue. In resection mode, if the module(s) detects apredetermined capacitance and/or impedance induced within conductivetraces 47 a, 47 b, generator 3 automatically initiates the transmissionof microwave energy to radiating section 6. Generator 3 automaticallyshuts off if radiating section 6 is inadvertently or purposefullyremoved from target tissue during transmission of microwave energytherefrom. This particular mode of operation allows a clinician torapidly change positions down a resection line without having tomanually turn the generator on and off.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. For example, while the aforementioned disclosure has beendescribed in terms of use of utilizing sensor 4 in conjunction fordetermining proper insertion of radiating section 6 into tissue, sensor4 may be utilized to determine other parameters that may associated withablation probe 2 and/or a surgical procedure. For example, sensor 4 maybe configured to detect tissue type, progression of a microwave ablationprocedure, completion of a microwave ablation procedure, etc. Moreover,in embodiments, sensor 4 may be utilized to detect the presence of acooling fluid that is being circulated through ablation probe 2 and/orcomponent associated therewith, e.g., shaft 22; this could mitigatecirculation errors, e.g., a clinician forgets to circulate fluid toradiating section 6. As can be appreciated, this may increase theoperative shelf life of radiating section 6 and/or ablation probe 2.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of particular embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of theclaims appended hereto.

What is claimed is:
 1. A method for manufacturing a microwave ablationprobe comprising: forming a housing configured to couple to a microwaveenergy source; forming a shaft defining a longitudinal axis, the shafthaving a pair of sensor contact pads and a radiating section forelectrosurgically treating tissue; forming a pair of sensor contactsthat couples to the interior of the housing; and coupling the shaft tothe housing such that each sensor contact pad of the pair of sensorcontact pads contacts a first portion of a corresponding one of thesensor contacts, the first portion of each of the pair of sensorcontacts extending perpendicularly from a second portion toward thelongitudinal axis defined by the shaft, the second portion of each ofthe pair of sensor contacts defining a longitudinal axis that extendsalong the longitudinal axis defined by the shaft.
 2. The methodaccording to claim 1, including forming the pair of sensor contact padson an exterior surface of the shaft via a silver ink deposition.
 3. Themethod according to claim 2, wherein forming the pair of sensor contactpads via the silver ink deposition includes utilizing a process selectedfrom the group consisting of pad printing, laser ablation and directwrite.
 4. The method according to claim 2, wherein forming the pair ofsensor contact pads via the silver ink deposition includes forming atleast two depositions that are spaced-apart from one another forming atleast two conductive traces that culminate at the sensor contact pads.5. The method according to claim 1, further comprising overmolding asensor housing to support at least a portion of the pair of sensorcontacts therein.
 6. The method according to claim 1, further comprisingbending each sensor contact such that a distal end of each sensorcontact is angled toward the other sensor contact.
 7. The methodaccording to claim 1, wherein coupling the shaft to the housing includesdisposing a proximal portion of the shaft within an interior of thehousing such that a distal portion of the shaft extends distally fromthe housing.
 8. A method for manufacturing an electrosurgical device,comprising: coupling an elongated shaft to a housing, the elongatedshaft defining a longitudinal axis and configured to electrosurgicallytreat tissue; and coupling a sensor contact pad disposed on theelongated shaft to a first portion of a sensor contact disposed withinthe housing, the first portion of the sensor contact extendingperpendicularly from a second portion of the sensor contact toward thelongitudinal axis defined by the elongated shaft.
 9. The methodaccording to claim 8, wherein the second portion of the sensor contactdefines a longitudinal axis that extends along the longitudinal axis ofthe elongated shaft.
 10. The method according to claim 8, furthercomprising coupling a pair of sensor contact pads disposed on theelongated shaft with a first portion of each of a pair of sensorcontacts disposed within the housing, the first portion of each of thepair of sensor contacts extending perpendicularly from a second portiontoward the longitudinal axis defined by the elongated shaft.
 11. Themethod according to claim 8, wherein coupling the elongated shaft to thehousing includes disposing a proximal portion of the elongated shaftwithin an interior of the housing such that a distal portion of theelongated shaft extends distally from the housing.
 12. The methodaccording to claim 8, wherein coupling the elongated shaft to thehousing includes coupling the sensor contact pad with a sensor contactsurface disposed on a distal end portion of the first portion of thesensor contact.
 13. A method for manufacturing an electrosurgicaldevice, comprising: disposing a sensor contact within a housing, thesensor contact having a first portion extending perpendicularly from asecond portion; and coupling an elongated shaft defining a longitudinalaxis to the housing to couple a sensor contact pad disposed on theelongated shaft with the first portion of the sensor contact, theelongated shaft configured to electrosurgically treat tissue.
 14. Themethod according to claim 13, wherein coupling the elongated shaft tothe housing includes positioning the elongated shaft such that alongitudinal axis defined by the second portion of the sensor contactextends along the longitudinal axis defined by the elongated shaft. 15.The method according to claim 13, wherein the first portion of thesensor contact extends perpendicularly from the second portion of thesensor contact toward the longitudinal axis defined by the elongatedshaft upon coupling the elongated shaft to the housing.
 16. The methodaccording to claim 13, wherein coupling the elongated shaft to thehousing includes coupling the sensor contact pad with a sensor contactsurface disposed on a distal end portion of the first portion of thesensor contact.
 17. The method according to claim 13, wherein couplingthe elongated shaft to the housing includes disposing a proximal portionof the elongated shaft within the housing such that a distal portion ofthe elongated shaft extends distally from the housing.